Cushion construction



Aug. 13, 1957 J. E. PETERSEN 2,802,517

CUSHION CONSTRUCTION Filed S ept. 1s, 1.955 E I s Sheets-Sheet 1 v v E vv- 2i 19 p6km6 @MW WE 1957 J. s. PETERSEN v 2,802,517

CUSHION CONSTRUCTION Filed Sept. 18, 1953 3 Sheets-Sheet 2 Aug. 13, 1957 J. s. PETERSEN 2,802,517

CUSHION CONSTRUCTION Filed Sept. 18, 1953 3 Sheets-Sheet 5 jmmzz Mad gkmew 1%! I g fftv/noggl CUSHION CONSTRUCTION John S. Petersen, Kenosha, Wis., assignor to Simmons Company, Kenosha, Wis., a corporation of Delaware Application September 18, 1953, Serial No. 381,071 I 8 Claims. 01. 155-179 This invention relates to upholstered cushions and is particularly concerned with an improved construction of so-called T-cushions.

In certain designs of upholstered chairs and sofas, the. arms of the chair or sofa terminate short of the, front edge of the seat, and in such cases the seat cushion: or portion thereof which is adjacent'each arm is usually provided with a sidewardly projecting car which extends outwardly to terminate flush with the side of the chair or sofa. In the case of a chair having a single cushion, the resulting configuration of the seat cushion is generally that of the letter T, but the general designation T- cushion is also applied to the side cushions of multiple cushion sofas, each of the side cushions in that case having only one such projection or ear.

It has been a general practice in the past, even when T-cushions were provided with inner spring constructions, to stuff the ear or cars of the cushion with padding and to provide an inner spring construction of generally rectangular shape in plan for only the main body of the cushion. The common experience has been that after considerable usage, a well defined breakf occursbetween the ear and the main'body of the cushion which, although not particularly detrimental from a purely functional standpoint, is objectionable from the standpoint ofappearance. I

It is therefore the principal object of this invention to provide an improved T-cushion construction in which the inner spring constructionv includes an integral ear portion which will prevent, throughout the useful life of the cushion, the unsightly break heretofore described, but which will, nevertheless, lend itself to machine assembly of the cushion in accordance with current manufacturing procedures.

i ed S tes. P t I Other objects and advantages appear and the in- Figure 1 is a perspective view of a sofa T-cushion,

partially broken away to illustrate the inner construction; Figure 2 is a foreshortened diagrammatic plan view of an inner spring construction in accordancewith the invention; i Figure 3 is an enlarged fragmentary plan view of a portion of Figure 2, showing in detailthe connection between the ear portion and the main body portion of the inner spring construction of a cushion in accordance with the invention; t

Figure 4 is an elevational view of the structure shown in Figure 3;

Figure 5 is a partial diagrammatic plan view of a modified form of the invention, especially adapted for cushions having ears of substantial length;

Figure 6 is an enlarged fragmentary plan view, similar to Figure 3, showing in greater detail the connectionbetween the ear portion and the mainbody portion of the modified spring construction of Figure 5.

seen to include an inner spring assembly or construc tion 13, hereinafter described in detail, a layer of pad ding 15 which preferably completely surrounds the construction 13, but which may, if desired, be of less thickness about the periphery of the cushion than beneath the seating surfaces thereof, and an outer envelope 17 of up holstery fabric or the like which encloses the spring con-a. struction and the padding, closely conforming thereto so as to be taut and neat appearing on all sides. v

, Referring to Figure 2, an inner spring construction 13 in accordance with the invention, comprises a main body portion 19 and an ear portionzl which,.although separately referred to, arenevertheless connected together to form an integral construction. The main body portion 19 includes a plurality of'rows of axially. vertical, wire;

coil springs 23, illustrated as being of the hour-glass type, although not necessarily so, each. of the springs 23 in a row being connected together in that row, and to the springs of the adjacent row, by means of helical tie wires 25 whichare threaded around overlapped portions of the top and bottom convolutions of springs in ad jacent rows, as is more or less common practice in opencoiltypes of inner spring construction. It will be noted that the individual coil springs 23 are so oriented about their own longitudinal axes that the knots 27, by means of which the extremities of the coil-forming wire are attached to the next adjacentconvolution of each spring, do not interfere with the helical tie wires 25 which con nect adjacent rows of springs together, nor with; the simicushions are subjected by the act of aypersonseating: himself in a chair. Although for the sakeof clarity oniy the upper half of the construction is shown in the, planviews (Figs. 2, 3, 5 ando), it will be appreciated, by'

reference to Figures 1 and 4, that tying helicalsZSare used in both the top and bottom planes of the'inner spring construction, and that the'orientatio'nof the heli: cals is the same in both planes so, thata'cushion embody-v ing the construction will be reversible."

In the embodiment shown. in Figures 2, 3 and k 'the ear portion 21 of the cushion includes a single similarly shaped coil spring 31 which is connected to the adjacentcoil spring 23 of the main body portion by short lengths of helical tie wires 33 threaded around the overlapped portions of the top and bottom convolutions of the two springs. The spring 31 in the ear portion, however, is

formed from wire of substantially heavier gauge, so that notwithstanding that its diameter is greater in the illustrated instance than that of the coils 23 in the main body portion of the construction, the coil 31 in the ear is stiffer than those in the main body portion and is capable of supporting greater loads per unit deflection than are the individual-coils in the main body portion of the cushion.

Inasmuch as the cushion is assembled by compressingthe springconstruction 13 and its surrounding padding 15 greater confining effect of the cushion envelope in that the cushion area, and thus to assure that the thickness of will be substantially uniform.

At the top and bottom faces of the construction, there is provided a border frame 35 in the form of a loop of wire which is similarly provided with an earto conform to the plan outline of the'spring construction. The bor der frames are connected to the marginal springs of the M Patented Aug. 13,

construction by means of the helical tie wire 29, which is similar to that used to connect adjacent rows of springs together, the tie wire 29 being threaded around the border, frames ,35- and the adjacent portions of the top and bottom convolutions of the marginal springs, includinglthe spring or springs which constitute the ear portion of the constructiontFigs. 3 and 4). In addition to the connection between the ear portion 21 and main body portion 19 effected by the short lengths of helical tie wire 33, the common attachment of all of the marginal springs, including those of the ear, to the border frame 35, securely integrates the ear with the main body portion of the construction.

The border frame 35 is preferably fabricated of flatspring wire or the equivalent, with the flat of the wire in the plane of the loop (Figs. 3 and 4) so as to provide greater stiffness in the plane of the construction for better shape retention; and greater flexibility in a direction normal to' the planejof the construction to prevent a permanent set in the border frames at the juncture of the ear and main body portions as a result of the bending which occurs in that area during normal use of the cushion.

In the modified form of inner construction 37 shown in Figures and 6, the main body portion 39 of the cushion, and the orientation of its spring coils 41 and other parts is generally the same as that described in connection with the embodiment of Figures 1 to 4 inclusive, the principal difference between 'the two forms being in the length of the ear portion 43, Le, its dimension measured sidewardly of the cushion. Where, as in Figures 5 and 6, the lengthlof the ear portion 43 is substantial, it is desirable to use two or more springs 45, which may, as shown par ticularly in Figure-6, be overlapped, depending upon the length of the-ear and the diameter of the springs, it being convenient to employ spring coils having a diameter equal to the desired width of the ear so as to provide secure attachments to the border frame 47 at opposite sides of the spring coils.

It will be apparent from the foregoing examples, that since the diameter of the coils in the ear is preferably equal to the desired width of the ear of the spring construction, it may in some instances be practicable to employ in the ear spring coils of the diameter of those used in .the main body of the construction. The ear coils individually 'may even be of the same weight and resiliencyas those in the main body of the construction providedv that a sufficient number of coils, overlapped, as in the case of Figs. 5. and 6, are used to provide an increased stitfness in theear portion of the construction to overcome the relatively greater confining effect of the ear portion of the cover envelope, in order that the thickness ofthe. completed cushion will be substantially uniform, Obviously, thereare practical. limits on the number-.of relatively softer" coils which can be overlapped or interfitted to achieve the desired increase in stiffness in the ear, inasmuch as the interengagement of convolutions of adjacent springs during the compression of the springs can. produce an undesirable clicking noise. In most applications, therefore, the increased stiffness of the ear portion of the construction will preferably be obtained by selecting fewer, but individually stiffer, springs.

Themachine assembly of inner spring cushions is usually effected by compressing the inner spring construction and its surrounding padding between two relatively mov-. able platens of a so-called filling machine, and slipping the pre-sewed envelope, which is left open at one-end, around the platens and the contained padding and spring construction. The padding and construction are then ejected from the space between the platens by means of a suitable ram, carrying with them the'enclosing envelope and being simultaneously emplaced within it. As the compressed padding and construction emerge from the confined space between the platens of the filling machine, they expand against the walls of the envelope, drawing the envelope taut. The cushion is then completed by sewing the final closure seam.

It will be apparent that cushions in accordance with the present invention, by proper orientation of their individual parts and suitable modification of the platens of a filling machine, lend themselves to machine assembly or filling without appreciably more difficulty than an ordinary cushion having no cars. For example, in the case of the single ear sofa type T-cushion illustrated in the drawings, the cushion is filled from the side opposite the ear, that is, with the ear of the padding and spring construction being the leading edge of the assembly as it emerges from the filling machine, in which case the final closure seam is made on the side of the cushion opposite the car.

In the case of a T-cushion having two cars, the cushion would necessarily be filled from the front and the final closure also made at the front.

An improved T-cushion having an inner spring construction provided with integral ears, in accordance with the invention, has a greater useful life than T-cushions of conventional construction because breaks between the ears and the main body of the cushion are effectively prevented, this being accomplished in the above-described construction without interfering with the assembly or filling of such cushions by machine method.

The features of the invention believed to be patentable are set forth in the appended claims.

I claim:

new and l. A removable upholstered cushion for chairs or the one spring and having greater resistance to vertical compression per unit area of seating surface than said body portion, all of said springs being double-ended and of substantially uniform height, top and bottom border frames conforming in plan to the outline of said construction and being secured to the marginal springs thereof, padding material surrounding said construction and a closely conforming envelope surrounding said padding and construction.

2. A removable upholstered cushion for chairs or the like comprising an inner spring construction including a main body portion of connected rows of axially vertical coil springs of substantially uniform weight and resiliency and a laterally projecting ear portion at at least one of the forward corners of said body portion, said ear portion comprising at least one coil spring of less resiliency than the coil springs of said body portion, all of said coil springs being double-ended and of substantially uniform height, top and bottom border frames conforming in plan to the outline of said construction and being secured to the marginal springs thereof, padding material surrounding said construction, and a closely conforming envelope surrounding said padding and construction.

3. A removable upholstered cushion for chairs or the likecomprising an innerspring construction including a main body portion of connected rows of axiallyvertical coil springs of substantially uniform weight and resiliency and a laterally projecting ear portion at at least one of the forward corners of said body portion, said ear portion comprising at least one coil spring of less resiliency than the coil springs of said body portion, all of said coil springs being double-ended and of substantially uniform height, top and bottom border frames conforming in'plan to the outline of said construction and being secured to the marginal springs thereof, said borderframes being formed of flat spring wire having its major cross sectional dimension disposed in the plane of the frame, padding material surrounding said construction, and a closely conforming envelopesurrounding said padding and construction.

4. A removable upholstered cushion for chairs or the like comprising an inner spring construction including a body portion and a laterally projecting ear portion at at least one of the forward corners of said body portion,

said body portion comprising axially vertical coil springs of substantially uniform weight and resiliency connected together in rows and to adjacent rows by top and bottom helical tie wires extending from front-to-rear of said construction, said ear portion comprising at least one coil spring of heavier weight and less resiliency than the springs of said body portion, all of said coil springs being double-ended and of substantially uniform height, top and bottom border frames conforming in plan to the outline of said construction and being secured to the marginal springs thereof, padding material surrounding said construction, and a closely conforming envelope surrounding said padding and construction.

5. An inner spring construction for removable T-cushions and the like comprising a main body portion and a laterally projecting ear portion at at least one of the forward corners of said body portion, said main body portion comprising connected rows of axially vertical coil springs, said ear portion comprising at least one spring and having more resistance to compression per unit area of seating surface of said cushion thansaid body portion, all of said springs being double-ended and of substantially uniform height, top and bottom border frames conforming in plan to the outline of said construction and being secured to the marginal springs thereof. 7

6. An inner spring construction for removable T-cushions and the like comprising a body portion and a sidewardly projecting ear portion at at least one of the forward corners of said body portion, said body portion comprising connected rows of axially vertical coil springs of substantially uniform weight and resiliency, said ear portion comprising at least one coil spring of heavier weight and less resiliency than the coil springs of said body portion, said one coil spring being connected to an adjacent coil spring of said body portion, all of said coil springs being double-ended and of substantially uniform height, top and bottom wire border frames conforming in plan to the outline of said construction and being secured to the marginal springs thereof.

7. An inner spring construction for removable T-cushions and the like comprising a body portion and a sidewardly projecting ear portion at at least one of the forward corners of said body portion, said body portion comprising axially vertical coil springs of substantially uniform weight and resiliency connected together in rows and to adjacent rows by top and bottom helical tie wires extending from front to rear of said construction, said ear portion comprising at least one coil spring of heavier weight and less resiliency than the coil springs of said body portion connected to an adjacent coil of said body portion, all of said coil springs being double-ended and of substantially uniform height, and top and bottom Wire border frames conforming in plan to the outline of said construction and being secured to the marginal springs thereof by helical tie Wires threaded around said border frames and the adjacent portions of the top and bottom convolutions of said marginal springs.

8. An inner spring construction for removable T-cushions and the like comprising a body portion and a sidewardly projecting ear portion at at least one of the forward corners of said body portion, said body portion comprising connected rows of axially vertical coil springs of substantially uniform weight and resiliency, said ear portion comprising at least one coil spring of heavier weight and less resiliency than the coil springs of said body portion connected to an adjacent coil of said body portion, all of said coil springs being double-ended and of substantially uniform height, and top, and bottom wire 7 border frames conforming in plan to the outline of said construction and being secured to the marginal springs thereof by helical tie wires threaded around said border loops and the adjacent portions of the top and bottom convolutions of said marginal springs, said border frames being formed of flat wire having its major crosssectional dimension disposed in the plane of said frame.

References Cited in the file of this patent UNITED STATES PATENTS 1,051,466 Travis Jan. 28, 1913 1,953,276 Suekoff Apr. 3, 1934 2,060,449 7 Singer et a1 Nov. 10, 1936 2,101,054 Eaton Dec. 7,1937 2,192,463 Wesley Mar. 5, 1940 2,265,426 Foster Dec. 9, 1941 2,609,865 Horton et a1 Sept. 9, 1952 

